MECON LIMITED

Indian Iron Ore Scenario : Low Grade Iron Ore Beneficiation

MECON LIMITED
A House of Engineering Excellence

INTRODUCTION

MECON LIMITED
A House of Engineering Excellence

INTRODUCTION
India is bestowed with large and rich sources of iron ore in terms of quantity and
quality with respect to world scenario

Draft National Steel Policy 2012 of India envisages the ambitious goal of
the nation to reach a production capacity of 300 Mt/yr of crude quality steel
by 2025 - 26.

The corresponding demand of iron ore containing 62 - 64 % Fe would be
around 490 Mt (excluding our export requirement).

The cut-off fixed by Indian Bureau of Mines is 45% Fe.

Previous washing methodology adopted had discarded the slimes as well as
fines containing Fe value between 45%-55% and have added 10-15 Mt
every year as Tailings.
So, it is the need of hour to effectively beneficiate low grade iron ore

MECON LIMITED
A House of Engineering Excellence

IRON ORE RESOURCE

IN
INDIA

MECON LIMITED
A House of Engineering Excellence

IRON ORE RESOURCE IN INDIA

India has vast minerals potential.

India occupies sixth position in iron ore
resource base

Ranks fourth with respect to world iron ore
production

India has around 8 percent of worlds deposit of iron ore.

The total resources of iron ore are estimates as 28.52 Billion Tonne

Classification of Hematite Ore
Grade

% Fe

(SiO2+Al2O3)%

High-grade

> 65% Fe

2% to 4%

Mediumgrade
Low-grade

62 - 65% Fe

6% to 8%

< 62% Fe

10% to 15%

MECON LIMITED
A House of Engineering Excellence

SLIME / FINES DUMP

The current mining methods generate a lot of fines, almost to the tune
of 60%.

Significant quantity of slimes, about 18 - 25 % of ROM has been
generated during wet processing of the high grade iron ore.

The amount of iron ore being lost in the tails is of the order of 10 - 15
Million tonnes per year.

These slimes have been accumulated in the tailing ponds in the mine
area and are posing environmental hazards.

These low grade slimes are readily available in finer size typically
assaying 55-60% Fe and 6-8% alumina, which has not been accepted
by sintering process.

MECON LIMITED
A House of Engineering Excellence

DRAFT NATIONAL STEEL

POLICY-2012

MECON LIMITED
A House of Engineering Excellence

DRAFT NATIONAL STEEL POLICY - 2012

The draft National Steel Policy 2012 aims at transforming Indian
steel industry into a global leader in terms of production,
consumption, quality and techno-economic efficiency while
achieving economic, environmental and social sustainability at par
with the developed world.
The major objective of draft NSP is to attract investments in
Indian steel sector from both domestic and foreign sources and
facilitate speedy implementation of investment intentions on board
so as to reach crude steel capacity level of 300 Million tonnes by
2025-26 to meet the domestic demand fully.

MECON LIMITED
A House of Engineering Excellence

IRON ORE REQUIREMENT TO MEET THE OBJECTIVE OF DRAFT NSP

Total Crude Steel - 300 Mt/yr

By 2025

Requirement

Processed Iron Ore Requirement : 490 Mt/yr (+62% Fe)

Balance
Reserve
(Hematite 55%
Cut off)

As on 2010, IBM
: 8093 Mt

ROM Requirement : 590 Mt/yr (Cut off 55% Fe)

Depletion
2010-15 :
776 Mt

As on 2015 : 7317
Mt

Projected Depletion
2015-25 : 3490 Mt

As on 2025 : 3800
Mt

Balance Life of Reserves beyond 2025: 6-7 Years

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A House of Engineering Excellence

NECESSITY OF BENEFICIATION
PROCESS

MECON LIMITED
A House of Engineering Excellence

NECESSITY OF BENEFICIATION PROCESS

Resource Augmentation & Utilization

Conversion of
Remaining Resources
in Reserves Category
Through Exploration
(>60 m depth & Fe-cut
off <50%) & Feasibility
Hematite : 9.8 Bt
Magnetite: 10.6 Bt
2014

Installation of slime
(50-60% Fe)
beneficiation plants

Beneficiation of
Existing Slimes ( 5060% Fe),
Sub grade Ore (45-55%
Fe) &
Future Slime & Low
Grade Ore (30-45% Fe)

2015

2020

Beneficiation
of sub grade
ore (45-55%
Fe)-5 Bt
(Unconf.)

Exploitation of
Magnetite
Resources

Eco-friendly Mining
Technology to Exploit
Vast Magnetite
Resources (Exploring
techno-economic
viability of U/G mining)

2025

Technology for low

grade ore (30-45%
Fe) utilisation

MECON LIMITED
A House of Engineering Excellence

NECESSITY OF BENEFICIATION PROCESS

In order to achieve the target steel production of 300 MT, 590MT of ROM
(when we are mining at 55% Fe cut-off) shall be required and after 2025
the reserves will last for 6-7 years.

Mining of hematite ore which we have left out having 45-55% Fe have to
be exploited in order to meet the future requirement after 2032. About 5.0
Bln tonnes low /sub grade hematite ore may be added to National resource
base since threshold value has been reduced to 45% Fe by IBM.

Magnetite ore in tune of 10.55 Bln tonnes, have not been exploited due to
its occurrence in eco-fragile/ sensitive area and due to restrictions imposed
by Honble Supreme Court. Eco-friendly Mining Technology to Exploit
vast Magnetite Resources and subsequent beneficiation of low grade
assaying 25-35% Fe have to be carried out to meet the steel industries
requirement.
In forthcoming scenario, it will be necessary by the mining industries to go for
beneficiation processes in techno-economic and environment friendly way in
order to ensure desired quality of iron ore for steel making.
MECON LIMITED
A House of Engineering Excellence

NECESSITY OF BENEFICIATION PROCESS

If the Fe value of the ore feed is less than 62%, productivity of Blast
furnace will be less because of use of more quantity of ore and high slag
volume.

More Silica that exists in the raw material more will be flux addition in
the furnace resulting in higher slag volume and lower productivity.

High alumina slag which is highly viscous requires larger quantity of flux
addition (8 - 12 % MgO) to make it fluid. The relatively larger slag
volumes will result in an increase in coke consumption.

It is estimated that a decrease in alumina content in the sinter from 3.1 to
2.5 will improve the RDI by at least six points, lowers- blast furnace coke
rate by 14 kg per tonne of hot metal and increase its productivity by about
30 % under Indian operating conditions.

MECON LIMITED
A House of Engineering Excellence

LOW GRADE IRON ORE

BENEFICIATION

MECON LIMITED
A House of Engineering Excellence

LOW GRADE IRON ORE BENEFICIATION

Techno-economic
studies
involving optimisation of flowsheet
based
on
test
results, finalisation of layout
and utility, capital cost
estimate,
operating
cost
estimate
and
financial
analysis have to be carried
out to evaluate the feasibility
of the beneficiation plant.
The technocrats have to
decide and evaluate the
suitable
flow
sheet
by
studying the cost implications
and financial analysis. The
cost
competitiveness
is
needed for survival in the
market and growth.

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A House of Engineering Excellence

NON CONVENTIONAL
PROCESS OF BENEFICIATION
Thermal Beneficiation
Bio Beneficiation

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A House of Engineering Excellence

Non Conventional Process of Beneficiation

Thermal Beneficiation

It is found that when crushed hematite ore (1 mm) is heated at 1,000oC
using microwave heating, it is converted into magnetite. It is then
subjected to Wet High Intensity Magnetic operation. About 40 % up
gradation is achieved by this process with 67 % Fe Concentrate.

Very low energy consumption method.

This process can utilize ultra low
grade hematite ore (25% Fe)

The steam generated in the
process is utilized in electricity
production.

MECON LIMITED
A House of Engineering Excellence

Non Conventional Process of Beneficiation

Bio Beneficiation

It has been found that many iron ore deposits have biogenetic origin
and are intimately associated with various types of microbes like fungus
Aspergillus niger and bacteria Bacillus Circulans

It is an eco- friendly, promising and revolutionary solution to high
energy and capital costs consumed in conventional beneficiation
techniques.
These non-conventional process of beneficiation have been tested at
laboratory scale with satisfactory results, but have yet to be proved at
pilot and commercial scale.

MECON LIMITED
A House of Engineering Excellence

MECON LIMITED
A House of Engineering Excellence